Decorative capped wheel nut or bolt assembly and method

ABSTRACT

A decorative cap and wheel nut or bolt insert assembly, and a method of assembling them. The insert is coated and/or plated and includes a hex-haped section and a section having a circular cylindrical outer surface. A cap includes a hex cross-section segment and a circular cylindrical cross-section segment. The hex cross-section segment of the cap slips easily over the hex section of the insert while the circular cylindrical cross-section segment has a smaller ID than the OD of the circular cylindrical insert section. The cap is formed of sheet material which is both plastically and elastically deformable. When pressed onto the insert, the cap deforms both plastically and elastically. An interference fit is formed between them by radial plastic deformation of the cap.

RELATED APPLICATION

This application is a continuation of application Ser. No. 10/303,564,filed Nov. 25, 2002, which is a continuation-in-part of application Ser.No. 09/828,662, filed Apr. 5, 2001, now abandoned. The disclosure ofapplication Ser. No. 10/303,564 is hereby incorporated herein byreference.

FIELD OF THE INVENTION

This invention relates generally to wheel nuts or bolts for securing avehicle wheel, i.e., a tire and rim, on a motor vehicle. It relatesparticularly to a decorative capped wheel nut or bolt assembly andassembly method.

BACKGROUND OF THE INVENTION

Decorative capped wheel nuts and bolts are well-known in the automotiveart. A decorative capped wheel nut assembly, for example, conventionallycomprises a nut insert and a decorative cap which is fastened to theinsert by welding, crimping or with an adhesive. Examples of theseconstructions are illustrated in various prior art patents, includingthe Toth U.S. Pat. No. 4,955,773, the Bydalek U.S. Pat. No. 5,772,377,the Chaivre U.S. Pat. No. 4,018,133, and U.S. Pat. No. 4,056,862, theBaltzell U.S. Pat. No. 4,764,070 and the Somers et al. U.S. Pat. No.6,036,420, for example. It is also known to form threads in a cap and ina lug nut and thread the cap onto the nut. See the Nolan et al. U.S.Pat. No. 5,180,266 in this regard.

All nut or bolt and cap assemblies described in the prior art requirerelatively complex fastening structures, assembly procedures and/oradditional components. Assemblies made by welding require expensive andsophisticated equipment for implementation of production. Practicaloptions for plating the inserts are limited where welding is employed,placing welded designs at a disadvantage for achieving high corrosionresistance. Crimped fastening designs require the addition ofcomponents, i.e., a sealant or O-ring, which complicates automatedassembly. The use of adhesives for fastening causes similar problems.Because of the nature of welding, or the use of additional components,production rates for these assemblies processes are low.

SUMMARY OF THE INVENTION

An object of the invention is to provide an improved decorative cappedwheel nut or wheel bolt assembly.

Another object is to provide a decorative capped wheel nut or wheel boltassembly wherein the decorative cap is secured to the nut or bolt insertwithout welding, applying an adhesive, or using a sealant or O-ring.

Yet another object is to provide a decorative cap and insert assemblywhich is simpler and less expensive, but just as reliable, as prior artassemblies.

Still another object is to provide a new and improved method ofassembling a decorative cap and nut or bolt insert.

The foregoing and other objects are realized in an insert and capassembly wherein the components are securely fastened together bycreating an interference fit between the cap and the insert.Specifically, the insert includes at least one section with a plated,coated or plated and coated circular cylindrical outer surface. The caphas a corresponding segment with a circular cylindrical inner surfacewhich has an inside diameter 0.010 to 0.030 inches smaller than theoutside diameter of the coated circular cylindrical outer surface. Thecap is fabricated of material which makes it radially deformable bothplastically and elastically. The insert is press fit into the cap,driving the cap's cylindrical inner surface over the insert's coatedcircular cylindrical outer surface. Radial plastic and elasticdeformation of the cap occurs. A 0.002 to 0.006 inches interference fitis formed around the interfering circular cylindrical surfaces by theelastic deformation of the cap.

In most applications of the invention, a straight cylindricalinterference fit is sufficient to retain the cap on the nut insertpermanently. In another aspect of the invention the cap rim may also becrimped, however. In yet another aspect, the cap rim may be thickenedand snap behind a shoulder on the insert.

The improved method of retaining a cap on the insert body requires onlytwo components, the cap and the insert, thus reducing the extra expenseof an additional component and the complexities of introducing thisextra component into the assembly process. It also allows the use of alltypes of coating, plating and coating or plating alone on the insert,which is not possible using current welding assembly methods. Furthercost savings may be achieved with higher assembly rates using simplehydraulic, pneumatic, or mechanical press equipment.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention, including its construction and method of operation, isillustrated more or less diagrammatically in the drawings, in which:

FIG. 1 is a side elevational view of a first embodiment of the inventionin a decorative capped wheel nut assembly;

FIG. 2 is a top plan view of the wheel nut assembly seen in FIG. 1;

FIG. 3 is a side elevational view of the nut insert for the decorativecapped wheel nut assembly seen in FIGS. 1 and 2;

FIG. 4 is a top plan view of the nut insert seen in FIG. 3;

FIG. 5 is a bottom plan view of the cap for the decorative capped wheelnut assembly seen in FIGS. 1 and 2;

FIG. 6 is a sectional view taken along line 6-6 of FIG. 2;

FIG. 7 is a diagrammatic illustration of an insert being press fit intoa cap in a mechanical press;

FIG. 8 is a side view, partially in elevation and partially in section,of a second embodiment of the capped invention;

FIG. 9 is a top plan view of the capped wheel nut assembly seen in FIG.8;

FIG. 10 is a split elevational/sectional view, similar to FIG. 8, of athird embodiment of the capped wheel nut assembly invention;

FIG. 11 is a top plan view of the capped wheel nut assembly seen in FIG.10;

FIG. 12 is a split elevational/sectional view, similar to FIG. 8, of afourth embodiment of the invention, a decorative capped wheel boltassembly;

FIG. 13 is a top plan view of the capped wheel bolt assembly seen inFIG. 12;

FIG. 14 is a split elevational/sectional view, similar to FIG. 8, of afifth embodiment of the invention, another decorative capped wheel boltassembly;

FIG. 15 is a top plan view of the capped wheel bolt assembly seen inFIG. 14;

FIG. 16 is a split elevational/sectional view, similar to FIG. 8, of asixth embodiment of the invention, another capped wheel nut assembly;

FIG. 17 is a top plan view of the capped wheel nut assembly seen in FIG.16;

FIG. 18 is a split elevational/sectional view, similar to FIG. 8, of aseventh embodiment of the invention, yet another capped wheel nutassembly;

FIG. 19 is a top plan view of the capped wheel nut assembly seen in FIG.18;

FIG. 20 is an enlarged portion of the assembly seen in FIG. 18; and

FIG. 21 is an enlarged portion of an assembly similar to that of FIG.20, showing a variation of the seventh embodiment assembly.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, and particularly to FIGS. 1-6, adecorative capped wheel nut assembly comprising a first embodiment ofthe present invention is seen generally at 10. The wheel nut assembly 10includes a nut insert 12 and a decorative cap 14 fastened securelytogether by a method embodying features of the invention.

FIGS. 1, 2 and 6 illustrate the wheel nut 10 assembly, i.e., anassembled nut insert 12 and cap 14. FIGS. 3 and 4 illustrate a nutinsert 12 separately. FIG. 5 illustrates a cap 14 separately (end view).

As seen in FIGS. 3, 4 and 6, the nut insert 12 comprises a body 21having a cylindrical bore 23 extending axially through it from ahex-shaped section 24 on one end to a frusto-conical base 25 on theother. The nut insert 12 is commonly referred to as a hex-nut insert andis fabricated in a conventional manner of carbon steel. Thefrusto-conical base 25 is adapted to seat in a conventional manner in awheel rim aperture (not shown) to fasten the wheel rim to a vehiclewheel stud (not shown). The bore 23 is internally threaded at its innerend 27 to receive the stud.

The nut insert 12 is coated in a conventional manner to preventoxidation of exposed areas. In the embodiment illustrated a coating ofGEOMET brand coating material available from Metal CoatingsInternational, Inc. of Chardon, Ohio, is applied. GEOMET is a coatingcomprised mainly of overlapping zinc and aluminum flake in an inorganicbinder, and is chromium free. It is applied over the entire insert 12 toa thickness of 0.001 inches.

Between the hex-shaped section 24 and the frusto-conical base 25, theinsert body 21 has two cylindrical body sections 31 and 33. The section31 of the illustrated insert body 21 has a cylindrical outer (coated)surface 35 with an outside diameter (OD) of 0.930 inches. The surface 35has an axial length of 0.130 inches. The section 33 has a cylindricalouter (coated) surface 39 with an OD of 0.955 inches. The surface 33 hasan axial length of 0.0625 inches. A radially extending shoulder 41 isformed between the two cylindrical surfaces 31 and 33.

As seen in FIGS. 2, 5 and 6, the cap 14 comprises three axially alignedwall segments; a dome-shaped end wall segment 51, a hex cross-sectionside wall segment 53 and a circular cylindrical side wall segment 55.The configuration and internal cross-sectional dimensions of thehex-shaped side wall segment 53 are such that it slips easily over thecoated, hex-shaped section 24 of the insert body. According to theinvention, however, as will hereinafter be further discussed, theinternal cross-sectional dimension of the circular cylindrical side wallsegment 55 is such that a predetermined elastic interference fit isformed between the inner surface 57 of the wall segment 55 and thecoated cylindrical outer surface 35 of the insert body 21 when the cap14 is press fit onto the insert 12.

The cap 14 is fabricated of stainless steel sheet with a nominalthickness of 0.018 to 0.020 inches. The inside diameter (ID) of thecylindrical wall segment 55 is preferably 0.910 inches. When the cap 14is pressed onto the insert 12, the cylindrical wall segment 55 undergoesboth plastic and elastic deformation. The portion of deformation that isplastic serves to allow a reasonable manufacturing tolerance for bothcomponents. The elastic deformation results in tensile hoop stresses inthe cap 14 and constitutes the mechanism by which the cap 14 is retainedon the insert 12. The resulting interference fit is approximately 0.0025inches around the interfering circular cylindrical surfaces as a resultof elastic deformation, but can vary with changes in cap wall thicknessor mechanical properties of the cap material.

FIG. 7 illustrates the assembly of a nut insert 12 into a cap 14 in asimple mechanical press P. The press P comprises a fixed die Dl in whichthe cap 14 is seated. A movable die D2 receives the insert 12 and drivesit downwardly onto the cap 14 under the influence of pressure exerted ina conventional manner by the mechanical press P. The fixed die D1receives the cap 14 in a well W. The well W is dimensioned to permit theradial expansion of the cylindrical side wall segment 55 which takesplace in the cap 14 as the insert 12 is press fit into the cap 14.

Referring now to FIGS. 8 and 9, a decorative capped wheel nut assemblycomprising a second embodiment of the invention is seen generally at110. The assembly 110 includes a nut insert 112 and a decorative cap 114fastened together according to the present invention.

The nut insert 112 comprises a body 121 having a cylindrical bore 123extending axially through it from a cylindrical section 131 on one endto a frusto-conical base 125 on the other. The base 125 is adapted toseat in a wheel rim aperture (not shown). The bore 123 is internallythreaded at 127. The insert 112 is coated in a manner previouslydiscussed.

Between the conical base 125 and the cylindrical section 131, there is ahex-shaped section 124. The hex-shaped section 124 corresponds to thehex section 24 in the insert body 21 of the assembly 10.

The axially outer, or end cylindrical section 131, has a coatedcylindrical outer surface 135 with an OD of 0.660 inches. The surface135 has an axial length of 0.190 inches.

As seen in FIG. 8 the cap 114, which is again formed from stainlesssteel sheet, comprises four axially aligned segments; a dome shaped endwall segment 151, a cylindrical side wall segment 155, a hex-shaped sidewall segment 153 and a frusto-conical lip 152. The configuration andinternal cross-sectional dimensions of the hex-shaped side wall segment153 are such that it slips easily over the coated hex-shaped section 124in the insert body 121.

The ID of the cylindrical wall segment 155 is 0.640 inches. When the cap114 is pressed onto the insert 112, the cylindrical wall segment 155undergoes both plastic and elastic deformation in the mannerhereinbefore discussed with relation to the cap 14. The elasticdeformation constitutes the mechanism by which the cap 114 is retainedon the insert 112. The resulting interference fit is approximately0.0025, again varying with changes in cap wall thickness or mechanicalproperties of the cap material.

Referring now to FIGS. 10 and 11, a decorative capped wheel nut assemblycomprising a third embodiment of the invention is seen generally at 210.The assembly 210 includes a nut insert 212 and a decorative cap 214fastened together according to the invention.

The nut insert 212 comprises a body 221 having a cylindrical bore 223extending axially through it from a cylindrical section 231 on one endto a frusto-conical base 225 on the other. The base 225 is adapted toseat in a wheel rim aperture (not shown). The bore 223 is internallythreaded at 227. Like the inserts 12 and 112, the insert 212 is coated.

Between the conical base 225 and the end cylindrical section 231 thereis a hex-shaped section 224. The hex-shaped section 224 corresponds tothe section 24 in the insert body 21 of the insert 12.

Between the hex-shaped section 224 and the frusto-conical base 225, theinsert body 221 has two cylindrical body sections 233 and 234. Theaxially outer cylindrical section 233 of the two has a coatedcylindrical outer surface 235 with an outside diameter (OD) of 0.930inches. The surface 235 has an axial length of 0.130 inches. A radiallyextending shoulder 241 is formed between the two cylindrical surfaces233 and 234.

The end cylindrical section 231 has a coated cylindrical outer surface236 with an OD of 0.660 inches. The surface 236 has an axial length of0.190 inches.

As seen in FIG. 11, the cap 214, again formed of stainless steel sheet,comprises four axially aligned segments; a dome shaped end wall segment251, an end circular cylindrical side wall segment 255, a hex-shapedside wall segment 253 and a circular cylindrical side wall segment 252.The configuration and internal cross-sectional dimensions of thehex-shaped side wall segment 253 are such that it will slip freely overthe coated hex-shaped section 224 in the insert body 221.

The ID of the cylindrical wall segment 255 is 0.640 inches. When the cap214 is pressed onto the insert 212, the cylindrical wall segment 255undergoes the aforedescribed plastic and elastic deformation as it isforced over the coated cylindrical surface 236. The resultinginterference fit is again approximately 0.0025.

The ID of the cylindrical side-wall segment 252 is 0.910 inches. Assuch, an interference fit of 0.0025 inches is effected at the same timebetween the side-wall segment 252 and the coated outer surface 235 ofthe end cylindrical section 231.

In FIGS. 12-15 the invention is seen in the context of a wheel boltrather than a wheel nut. Referring specifically to FIGS. 12 and 13, adecorative capped wheel bolt assembly comprising a fourth embodiment ofthe invention is seen generally at 310. The assembly 310 includes a boltinsert 312 and a decorative cap 314.

The bolt insert 312 comprises a bolt body 321 fabricated of carbon steelin a conventional manner. The body 321 includes a hex-shaped section 324at one end and an externally threaded base 327 at the opposite end. Theinsert 312 is coated in a manner previously discussed.

Between the hex-section 324 and the threaded base 327, a circularcylindrical section 331 and a frusto-conical section 333 are formed. Thecircular cylindrical section 331 has a coated cylindrical outer surface335. The OD of surface 335 is 0.895 inches. The surface 335 has an axiallength of 0.165 inches.

The frusto-conical section 333 is adapted to seat in a wheel rimaperture (not shown) to fasten the wheel rim to a vehicle wheel. Thethreaded base 327 of the insert 312 threads into the wheel hub in a wellknown manner.

The cap 314, again formed from stainless steel sheet, comprises threeaxially aligned segments, a dome shaped end wall segment 351, ahexshaped side wall segment 353 and a cylindrical side wall segment 355.The configuration and internal cross-sectional dimensions of thehex-shaped side wall segment 353 are such that it slips easily over thecoated hex-shaped section 324 in the insert body 321.

The ID of the cylindrical wall segment 355 is 0.875 inches. When the cap314 is pressed onto the insert 312, the cylindrical wall segment 355undergoes the aforedescribed plastic and elastic deformation as it isforced over the coated surface 335 on the bolt body 321. The resultinginterference fit is again approximately 0.0025 inches.

Referring now to FIGS. 14 and 15, a decorative capped wheel boltassembly comprising a fifth embodiment of the invention is seengenerally at 410. The assembly 410 also includes a bolt insert 412 and adecorative cap 414.

The bolt insert 412 comprises a bolt body 421 fabricated of carbon steelin a conventional manner. The body 421 includes a hex-shaped section 424near one end and an externally threaded base 427 at the opposite end.The insert 412 is coated in a manner previously discussed.

Axially outwardly of the hex-section 424, the insert 412 includes acircular cylindrical section 431. The circular cylindrical section 431has a coated cylindrical outer surface 435. The OD of surface 435 is0.615 inches. The surface 435 has an axial length of 0.150 inches.

The insert 412 also has a spherical section 433 adapted to seat in aconventional manner in a wheel rim aperture (not shown) to fasten thewheel rim to a vehicle wheel. The threaded base 427 of the insert 412threads into the wheel in a well known manner.

The cap 414, again formed from stainless steel sheet, comprises threeaxially aligned segments; a dome shaped end wall segment 451, acylindrical side wall segment 455, a hex-shaped side wall segment 453and a flared lip 456. The configuration and internal cross-sectionaldimensions of the hex-shaped side wall segment 453 are such that itslips easily over the coated hex-shaped section 424 in the insert body421.

The ID of the cylindrical wall segment 455 is 0.595 inches. When theinsert 412 is pressed into the cap 414, the cylindrical wall segment 455undergoes the aforedescribed plastic and elastic deformation. As it isforced over the coated cylindrical surface 435 on the bolt body 421, aninterference fit of approximately 0.0025 inches is effected around thecoated surface 435.

FIGS. 16 and 17 illustrate yet a sixth embodiment of a capped wheel nutassembly embodying features of the invention at 510. The assembly 510includes a nut insert 512 and a decorative cap 514.

The nut insert 512 comprises a body 521 having a cylindrical bore 523extending axially through it from a hex-shaped section 524 on one end toa frusto-conical base 525 on the other. The base 525 is adapted to seatin a wheel rim aperture (not shown). The bore 523 is internally threadedat 527. Like the inserts 12 and 112, the insert 512 is coated.

Between the hex-shaped head 524 and the frusto-conical base 525, theinsert body 521 has a body section 533. The body section 533 of theillustrated insert body 521 has a coated cylindrical outer surface 535with an OD of 1.160 inches and an axial length of 0.130 inches. Belowthe cylindrical body section surface 535, and above the frusto-conicalbase 525, there is an undercut 534.

The cap 514 comprises three axially aligned wall segments; a dome-shapedend wall segment 551, a hex cross-section side wall segment 553, acircular cylindrical side wall segment 555 and a crimp section 556. Theconfiguration and internal cross-sectional dimensions of the hex-shapedside wall segment 553 are such that it slips easily over the coated,hex-shaped section 524 of the insert body (before the inward crimpsection 556 is formed). The internal cross-sectional dimension of thecircular cylindrical side wall segment 555 is such that a predeterminedinterference fit is formed between the inner surface 557 of the wallsegment 555 and the coated cylindrical outer surface 535 of the insertbody 521 when the cap 514 is press fit onto the insert 512.

The cap 514 is fabricated of stainless steel sheet with a nominalthickness of 0.018 to 0.020 inches. The inside diameter (ID) of thecylindrical wall segment 555 is preferably 1.140 inches. The cap 514 ispressed onto the insert 512 and the cylindrical wall segment 555undergoes plastic and elastic deformation. The resulting interferencefit is approximately 0.0025.

In this embodiment of the invention, the crimp section 556 is formedinwardly after the insert 512 is press fit into the cap 514 in theaforedescribed manner. Crimping may be accomplished as a continuation ofthe press-fit operation. The crimp section 556 is crimped intoengagement with the undercut 534 on the insert body 521. The crimpfeature is offered as an option where the assembly 510 may be subject toextreme wrenching abuse, and assures that it will remain intact undersuch conditions. It also provides a pleasing decorative appearance tothe assembly. The interference fit and the crimp then both serve to holdthe cap 514 securely on the insert 512 with the interference fit servingthe further function of blocking the entry of moisture at the junctureof surfaces 535 and 557.

FIGS. 18-20 illustrate a seventh embodiment of a capped wheel nutassembly embodying features of the invention at 610. The assembly 610includes a nut insert 612 and a decorative cap 614.

The nut insert 612 comprises a body 621 having a cylindrical bore 623extending axially through it from a hex-shaped section 624 on one end toa frusto-conical base 625 on the other. The base 625 is adapted to seatin a wheel rim aperture (not shown). The bore 623 is internally threadedat 627. Like the inserts 12 and 112, the insert 612 is coated.

Between the hex-shaped head 624 and the frusto-conical base 625, theinsert body 621 has a body section 633. As best seen in FIG. 20, thebody section 633 of the illustrated insert body 621 has a coatedcylindrical surface 635 adjacent the base 625 which has an axial lengthof 0.180 inches. The coated cylindrical surface 635 includes a firstcylindrical surface 641 having an OD of 0.910 inches and an axial lengthof 0.070 inches and a second cylindrical surface 642 having an OD of0.890 inches and an axial length of 0.110 inches. An annular shoulder643 having a width of 0.010 inches is, thus, formed between the firstand second surfaces 641 and 642.

The cap 614 comprises three axially aligned wall segments; a dome-shapedend wall segment 651, a hex cross-section side wall segment 653 and agenerally circular cylindrical side wall segment 655. The configurationand internal cross-sectional dimensions of the hex-shaped side wallsegment 653 are such that it slips easily over the coated, hex-shapedsection 624 of the insert body.

The circular cylindrical side wall segment 655 includes a lip 656 foldedback inside the wall segment. As seen in FIG. 20, the lip 656 doublesthe wall segment 655 thickness at its outer end, as seen at 657.Coextensive with the lip 656, the wall segment 655 is also formedslightly outwardly so that the double thickness portion 657 of it iseffectively centered under the segment 655.

The cap 614 is fabricated of stainless steel sheet with a nominalthickness of 0.018 to 0.020 inches. The inside diameter (ID) of thecylindrical wall segment 655 not covered by the lip 656 is preferably0.890 inches. The cap 614 is pressed onto the insert 612 and thecylindrical wall segment 655 undergoes plastic and elastic deformation.The resulting interference fit between the first cylindrical surface 641and wall segment 655 is approximately 0.0025 inches.

In effect, both the wall segment 655 not covered by the lip 656 and thedouble thickness portion 657 of the wall segment 655, 656 including thelip, stretch radially outwardly as the cap 614 is pressed on to theinsert 612. When the lip 656 passes the shoulder 643, it snaps radiallyinwardly due to the elastic component of the deformation, effectivelylocking the cap on the nut insert.

Referring now to FIG. 21, a variation of the seventh embodiment cappedwheel nut assembly 610 is seen at 710. The assembly 710 is very similarin construction and operation to the assembly 610, so only differencesare described. Reference numerals which correspond to those of theassembly plus 100 digits are employed.

In the assembly 710, the circular cylindrical wall segment 755 of thecap 714 has an axially longer cylindrical lip 756, and the shoulder 743is located accordingly. No offset is formed in the wall segment 755 sothe double thickness portion 757 is not centered under the remainder ofthe wall segment 755.

The cylindrical surface 742 adjacent the shoulder 743 has an outsidediameter of 0.890 inches. The inside diameter of the cylindrical lip 756is 0.870 inches. When the cap 714 is press fit onto the insert 714, thewall segment 755 and lip 756 undergo plastic and elastic deformation. Aninterference fit between the lip 756 and the surface 742 isapproximately 0.0025 inches.

It should be pointed out at this point that the various insertsdescribed might be plated first and then coated. They might also beplated in a conventional manner and not coated. The inventioncontemplates employing any of these approaches to protect a carbon steelinsert from the elements. It should also be understood that althoughonly the third embodiment assembly 210 (FIGS. 10 and 11) illustratesusing separate interference fits at two axially spaced, matingcylindrical surfaces, the invention contemplates the use of either oneor two sets of mating cylindrical surfaces in any embodiment, as amatter of choice.

While preferred embodiments of the invention have been described, itshould also be understood that the invention is not so limited andmodifications may be made without departing from the invention. Thescope of the invention is defined by the appended claims, and alldevices that come within the meaning of the claims, either literally orby equivalence, are intended to be embraced therein.

1. A decorative cap and wheel fastener assembly for a vehicle wheel,comprising: a) a fastener insert body having threads formed thereonencircling the axis of said body; b) said body including one sectionhaving an external surface with a polygonal cross-section encirclingsaid axis; c) said body including another section having an externalsurface with a circular cylindrical cross-section encircling said axis;and d) a cap including one wall segment having an internal surface witha polygonal cross-section; e) said cap further including another wallsegment having an internal surface with a circular cylindricalcross-section, said wall segment being formed of sheet material which isradially deformable both plastically and elastically; f) said insertbody and said cap being assembled by being press fit together, saidcircular cylindrical cross-section surface on said body being greaterthan the unassembled internal dimensions of said circular cylindricalcross-section surface in said other wall segment of said cap wherebysaid other wall segment is plastically and elastically deformed radiallyoutwardly to form an interference fit between said other wall segmentand said other body section when said insert body and said cap areassembled, said elastic deformation being at least 0.002 inches radiallyoutwardly around the entire circumference of said cap.
 2. The cap andfastener assembly of claim 1 further characterized in that: a) saidexternal surfaces of said insert body are coated; b) said coating isapproximately 0.001 inches thick.
 3. The cap and fastener assembly ofclaim 1 further characterized in that the diameter of said internalcylindrical surface in said cap is 0.010 to 0.030 less than the diameterof said external cylindrical surface on said insert prior to assembly ofsaid cap and wheel fastener whereby said cap is deformed plastically andelastically at least 0.0025 inches radially.
 4. The cap and fastenerassembly of claim 2 further characterized in that: a) said coating ischromium free.
 5. The cap and fastener assembly of claim 1 furthercharacterized in that: a) said elastic deformation is between 0.002 and0.006 inches around the said external and internal circular cylindricalsurfaces.
 6. The cap and fastener assembly of claim 1 furthercharacterized in that: a) said internal polygonal surface is seated oversaid external polygonal surface on said insert in a non-interference fitrelationship.
 7. The cap and fastener assembly of claim 1 furthercharacterized in that: a) said insert body includes another sectionhaving an external surface with a circular cylindrical cross-section,said other body section being separate from said one body section; andb) said cap includes another wall segment having an internal surfacewith a circular cylindrical cross-section; c) an interference fit alsobeing established between said other external and internal circularcylindrical surfaces.
 8. The cap and fastener assembly of claim 1further characterized in that: a) said cap including a crimp segment;and b) said insert body including an undercut which is engaged by saidcrimp segment.
 9. The cap and fastener assembly of claim 1 furthercharacterized in that: a) said one circular cylindrical surface on saidinsert body has an outside diameter of about 0.930 inches.
 10. The capand fastener assembly of claim 1 further characterized in that: a) ashoulder is formed in said circular cylindrical surface on said insert;and b) said cap having an annular free edge which seats under saidshoulder.
 11. A method of assembling a decorative cap and wheel nut orbolt insert comprising the steps of: a) forming an insert with a sectionhaving a polygonal external cross-section axially displaced from asection having circular cylindrical external cross-section; b) applyinga plating and/or a coating to the insert so at least the exterior ofsaid section having an external circular cylindrical section is platedand/or coated; c) forming a decorative cap of sheet material with asegment leaving a polygonal cross-section and a segment having acircular cylindrical cross-section axially displaced from each other,the polygonal cross-section segment having internal dimensions greaterthan the corresponding external dimensions of said polygonal section onsaid insert and the circular cylindrical cross-section segment havinginternal dimensions less than the corresponding external dimensions ofsaid circular cylindrical section on said insert; and d) press fittingsaid insert into said cap so as to form an interference fit between theplated and/or coated circular cylindrical surfaces of said insert andthe circular cylindrical surface of said cap.
 12. The method of claim 11further characterized in that: a) said insert is coated with a chromiumfree coating material.
 13. The method of claim 11 further characterizedin that: a) an interference fit of between 0.002 and 0.006 inches isformed between said circular cylindrical surfaces.
 14. The method ofclaim 13 further characterized by and including the step of: a) crimpingan edge of said cap under a mating undercut on said insert body.
 15. Theassembly of a decorative cap and wheel fastener insert for a vehiclewheel, comprising: a) a fastener insert body having threads formedthereon encircling the axis of said body; b) said body including onesection having an external surface with a polygonal cross-sectionencircling said axis; c) said body further including another sectionhaving an external surface with a circular cylindrical cross-sectionencircling said axis; d) a cap including one wall segment having aninternal surface with a polygonal cross-section; e) said cap furtherincluding another wall segment having an internal surface with acircular cylindrical cross-section; and f) said cap being formed ofplastically and elastically deformable sheet material and thecross-sectional dimensions of said internal cylindrical surface in saidcap being less than the cross-sectional dimensions of said cylindricalsurface on said body whereby when the wheel fastener insert and the capare assembled said one wall segment is plastically deformed radiallyoutwardly of said axis for a distance of at least 0.002 inches.
 16. Thecap and fastener assembly of claim 15 further characterized in that: a)said external surfaces are coated with another material to a thicknessof approximately 0.001 inches.
 17. The cap and fastener assembly ofclaim 16 further characterized in that: a) said coating material ischromium free.
 18. A decorative cap and wheel fastener combination for avehicle wheel, comprising: a) a fastener insert body having threadsformed thereon encircling the axis of said body; b) said body includingone section having an external surface with a polygonal cross-sectionencircling said axis; c) said body further including a section having anexternal surface with a circular cylindrical cross-section encirclingsaid axis; and d) a cap including a wall segment having an internalsurface with a polygonal cross-section; e) the cross-sectionaldimensions of said internal polygonal surface in said cap being at leastas large as the cross-sectional dimensions of said external polygonalsurface on said body; f) said cap further including one wall segmenthaving an internal surface with a circular cylindrical cross-section; g)the cross-sectional dimensions of said internal cylindrical surface insaid cap being less than the cross-sectional dimensions of saidcylindrical surface of said body; h) said insert body adapted to bepress fit into said cap whereby an interference fit will be establishedbetween said one external and internal circular cylindrical surfaces.19. The cap and fastener assembly of claim 18 further characterized inthat: a) said cap is formed of plastically and elastically deformablesheet material. b) the diameter of said internal cylindrical surface insaid cap is 0.010 to 0.030 less than the diameter of said externalcylindrical surface on said insert.
 20. The cap and fastener assembly ofclaim 18 further characterized in that: a) said cap is formed ofelastically deformable sheet material and includes a free edge on saidone wall segment which is folded back inside said one wall segment; andb) said insert includes a shoulder under which said free edge seats inlocking relationship.